US4579168A - Making metal strip and slab from spray - Google Patents

Making metal strip and slab from spray Download PDF

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Publication number
US4579168A
US4579168A US06/707,471 US70747185A US4579168A US 4579168 A US4579168 A US 4579168A US 70747185 A US70747185 A US 70747185A US 4579168 A US4579168 A US 4579168A
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US
United States
Prior art keywords
spray
rolls
nip
slab
strip
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Expired - Lifetime
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US06/707,471
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English (en)
Inventor
Alfred R. E. Singer
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BTG International Ltd
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National Research Development Corp of India
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Assigned to NATIONAL RESEARCH DEVELOPMENT CORPORATION, 101 NEWINGTON CAUSEWAY, LONDON SE1, 6BU ENGLAND A BRITISH CORP reassignment NATIONAL RESEARCH DEVELOPMENT CORPORATION, 101 NEWINGTON CAUSEWAY, LONDON SE1, 6BU ENGLAND A BRITISH CORP ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: SINGER, ALFRED R. E.
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Publication of US4579168A publication Critical patent/US4579168A/en
Assigned to BRITISH TECHNOLOGY GROUP LIMITED reassignment BRITISH TECHNOLOGY GROUP LIMITED ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: NATIONAL RESEARCH DEVELOPMENT CORPORATION
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D23/00—Casting processes not provided for in groups B22D1/00 - B22D21/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00—Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/06—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars
    • B22D11/0622—Continuous casting of metals, i.e. casting in indefinite lengths into moulds with travelling walls, e.g. with rolls, plates, belts, caterpillars formed by two casting wheels

Definitions

  • This invention relates to a process for making metal strip and slab from spray.
  • this substrate is very smooth, the first particles to land on it will detach themselves under their internal shrinkage stresses as they cool, leading to a very porous layer having insufficient cohesion between the splats for the layer to be removed from the substrate and hot-worked into a strip.
  • this substrate is very rough, the particles landing on it will attach themselves so securely that the layer cannot be detached when required.
  • a slightly rough (such as lightly grit-blasted) surface is preferred, and the first particles to land on it will be least likely to detach themselves prematurely if they land substantially orthogonally, hence a further preference, in this known process, for a spray whose axis is at or near 90° to the substrate.
  • the deliberate slight roughness of the substrate is transferred to the deposited layer, which can be made smooth by further working.
  • the present invention is a process for making metal strip and slab, wherein a spray of molten metal is directed towards a nip formed by two smooth cooled rolls, the rolls being rotated so that the nip hot-compacts the sprayed metal to yield a strip or slab emerging from the exit of the nip.
  • the smooth cooled rolls should be such that splats formed by droplets of the molten spray impinging on the rolls before reaching the nip do not stick completely to the roll surfaces but at least partially detach themselves on freezing and form a new surface on which subsequent droplets of the spray land; when the nip is reached, the partially detached frozen droplets and their overlying deposit, on both rolls, are compacted hot.
  • the angle subtended by the outermost parts of the spray is preferably less than half the angle subtended at the origin of the spray by the axes of the rolls and the centre line of the spray is directed tangentially towards the rolls or not very far off tangentially.
  • Molten steel in a heated tundish 1 is formed, by a process according to the invention, into a strip 7 some 20 cm wide and 1/2 mm thick.
  • the tundish 1 is fitted with an 8 mm-diameter bottom-pouring nozzle 2 and a stopper 3.
  • the molten steel descends from the nozzle 2 as a cylindrical stream 4 to be met by primary atomising jets of nitrogen at 400 kNm -2 from a gas atomiser 5, which breaks up the stream 4 into small molten droplets.
  • the process takes place in a chamber 8 which effectively excludes atmospheric air and ensures that the atomised particles are wholly surrounded by nitrogen.
  • the chamber 8 is fitted with seals where it meets the rolls 6.
  • a scanning device is fitted to the atomiser as described in UK Patent Specification No. 1455862 to scan the spray at 50 Hz in a direction normal to the plane of the paper so as to distribute the sprayed particles uniformly axially along the rolls.
  • the outer particles will splat on the smooth roll surface 11, cool extremely rapidly and become at least partly detached from the roll surface thus protecting the roll from the hotter inner particles 12 which will land on top of them pressing them against the roll and also sliding them downwards into the roll nip 13.
  • these initial splats together with the overlying ones will receive further liquid particles from the centre of the spray 10 after which the combined sandwich is rolled to produce solid strip 7.
  • the height of the atomiser 5 is such that the angle ⁇ s subtended by the spray, being 41°, is less than half the angle ⁇ r (84°) subtended where the spray is formed by the axes of the rolls 6.
  • spent atomising gas should move away from the area of deposition without carrying with it any wasteful proportion of the spray particles. This is accomplished in two ways which may be used singly or combined.
  • the spray is distributed uniformly along the axial extent of the rolls by a scanning device.
  • the action of scanning has a special advantage in that it allows easy escape of gas in a direction generally parallel to the axes of the rolls.
  • Such scanning action can be oscillatory (i.e. backwards and forwards, reversing direction at the end of such sweep), or it can be unidirectional only.
  • the structure of the strip or slab is more uniform and the eflux of gas is mainly in the axial direction and in the sense of the sweep.
  • Cooling of the rolls is an important element in the operation because in the manufacture of thin strip by the process of the invention part of the latent heat of solidification is absorbed by the rolls. Water cooling internally is advisable and roll surface water cooling may also be necessary, but in this latter case the roll surfaces must be completely dry before being re-presented to the molten metal spray, otherwise undesirable reaction or explosion may occur. In the making of thick strip or slab by the process of the invention, roll cooling is equally necessary but secondary cooling becomes more important, such as by jets of water sprayed on the emerging thick strip or slab.
  • a second example according to the invention is the horizontal spray casting of a 30 mm thick slab of aluminium alloy 500 mm wide.
  • the roll gap is set at approximately the thickness of the slab required.
  • a steel starter slab of slightly smaller thickness but similar width is inserted from the withdrawal side between the rotating rolls to a position approximately in the plane containing both roll axes, which plane is vertical, the axes being horizontal.
  • the starter slab has a serrated tongue projecting slightly beyond the line of centres, to ensure that the spray deposit will adhere strongly to it.
  • the stream of molten aluminium alloy is atomised, directed generally horizontally and then scanned (keeping it generally horizontal) so that the centre portion of the spray is directed into the nip approximately tangentially to the rolls, with the outer parts (penumbra) of the spray impacting the roll surfaces at an angle of approximately 40°.
  • the splats formed by the impact of the outer parts of the spray solidify, loosen from the smooth roll surface and are propelled into the nip where they are met by droplets from the centre part of the spray. Any liquid stays where it is, by surface tension. The result is that a partially frozen mass of aluminium alloy approximately 50 mm in thickness accumulates in the nip of the rolls.
  • Extraction of heat from the aluminium alloy is partly by means of the cooled rolls, partly by cooling of the deposit by radiation and by contact with the relatively cool spent atomising/scanning gas and partly by secondary cooling of the slab by water sprays beyond the exit of the roll nip.
  • the scanning spray covers the whole axial extent of the rolls and therefore necessarily leads to some overspray.
  • This powder can be collected and re-introduced into the atomiser entrained in the same gas as is used for atomising the liquid stream.
  • Such entrained powder can conveniently be introduced tangentially between the metal stream and the primary atomising nozzles as described in British Patent Publication No. 2115014A.
  • the overspray powder introduced in this way is incorporated into the spray casting and brings the double advantage of improving the overall yield and increasing the cooling rate of the spray casting.
  • the rolling reduction given during the manufacture of slab may be quite small, say 1 to 5%, in which case it consolidates the surface layers and reduces any porosity in the interior without causing appreciable extension of the slab, or it may be a substantial reduction, as in the second example, causing appreciable plastic deformation and extension of the slab.
  • An alternative procedure in the case of the spray forming of slabs is to provide edge dams at the edges of the barrel of the rolls. These reduce overspray but need to be moved in the direction of rolling to avoid the accumulation of adherent particles. They also tend to restrict the flow of spent gas away from the deposition area. Ancillary gas jets may be directed at the edges, pointing inwards to reduce overspray but these also tend to interfere with the flow of spent atomising gas.
  • the two examples show production of strip or slab by spraying into the nip of a rolling mill both vertically downwards and horizontally.
  • Other configurations are also operable, because no substantial pool of molten metal exists at any time in the nip of the rolls, whereby the process operates independently of gravity as far as deposition and compaction are concerned.
  • the freedom given by the absence of a pool of liquid metal enables the process to be so arranged as to feed as conveniently as possible into subsequent manufacturing operations.
  • the rolls need not be of the same diameter, nor need they turn at the same speed as long as they produce strip or slab, nor need they be plain; that is, they may be profiled, for producing profiled strip or slab, as long as their surfaces are functionally smooth.
  • slab there may be some advantage to be gained by using one roll smaller than the other in which case the strip or slab will exit at an angle inclined towards the smaller roll. This may be useful when it is required to turn the strip or slab into a convenient direction for subsequent rolling, cutting or annealing.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)
  • Metal Rolling (AREA)
  • Powder Metallurgy (AREA)
  • Coating By Spraying Or Casting (AREA)
US06/707,471 1984-03-07 1985-03-01 Making metal strip and slab from spray Expired - Lifetime US4579168A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB8405982 1984-03-07
GB848405982A GB8405982D0 (en) 1984-03-07 1984-03-07 Making metal strip and slab from spray

Publications (1)

Publication Number Publication Date
US4579168A true US4579168A (en) 1986-04-01

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ID=10557722

Family Applications (1)

Application Number Title Priority Date Filing Date
US06/707,471 Expired - Lifetime US4579168A (en) 1984-03-07 1985-03-01 Making metal strip and slab from spray

Country Status (6)

Country Link
US (1) US4579168A (de)
EP (1) EP0155791B1 (de)
JP (1) JPH0736939B2 (de)
CA (1) CA1215520A (de)
DE (1) DE3570381D1 (de)
GB (2) GB8405982D0 (de)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4738712A (en) * 1985-04-19 1988-04-19 National Research Development Corporation Metal forming
US4834832A (en) * 1985-09-04 1989-05-30 Wacker-Chemitronic Gesellschaft Fur Elektronik-Grundstoffe Mbh Process and apparatus for the manufacture of silicon rods
US5343926A (en) * 1991-01-02 1994-09-06 Olin Corporation Metal spray forming using multiple nozzles
US6063212A (en) * 1998-05-12 2000-05-16 United Technologies Corporation Heat treated, spray formed superalloy articles and method of making the same
US6296043B1 (en) 1996-12-10 2001-10-02 Howmet Research Corporation Spraycast method and article
CN100374612C (zh) * 2005-12-26 2008-03-12 内蒙古科技大学 金属雾化喷射连续生产双金属薄板、薄带的工艺及设备
CN106552908A (zh) * 2016-12-02 2017-04-05 苏州金江铜业有限公司 一种短流程高纯铍箔制备方法

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2172900A (en) * 1985-03-25 1986-10-01 Osprey Metals Ltd Making thixotropic metal by spray casting
GB8507647D0 (en) * 1985-03-25 1985-05-01 Osprey Metals Ltd Manufacturing metal products
GB8507674D0 (en) * 1985-03-25 1985-05-01 Atomic Energy Authority Uk Metal matrix composite
GB2174411B (en) * 1985-04-19 1989-06-28 Nat Res Dev Metal casting
GB2267715B (en) * 1992-06-03 1995-11-01 British Steel Plc Improvements in and relating to the production of high silicon-iron alloys
GB2271733B (en) * 1992-10-20 1996-07-03 British Steel Plc Improvements to the continuous spray forming of metal strip
KR100852488B1 (ko) 2006-11-03 2008-08-18 한성석 금속판재 제조장치
KR100888812B1 (ko) 2007-01-23 2009-03-13 한성석 금속적층체 제조장치
CN110695327B (zh) * 2019-11-14 2021-08-03 瓯锟科技温州有限公司 一种铝合金复合板带的喷射轧制制备方法

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1262471A (en) * 1968-05-14 1972-02-02 Nat Res Dev Improvements relating to the fabrication of articles
US4114251A (en) * 1975-09-22 1978-09-19 Allegheny Ludlum Industries, Inc. Process for producing elongated metal articles
JPS5573448A (en) * 1978-11-24 1980-06-03 Matsushita Electric Ind Co Ltd Quick solidifying method of melt
JPS5732854A (en) * 1980-08-08 1982-02-22 Hitachi Ltd Producing device for amorphous metallic tape
JPS5788951A (en) * 1980-11-19 1982-06-03 Sanyo Electric Co Ltd Production of anode blank material for electrochemical potential storage element
GB2115014A (en) * 1982-02-23 1983-09-01 Nat Res Dev Method of making a two-phase or multi-phase metallic material
US4420441A (en) * 1982-02-23 1983-12-13 National Research Development Corp. Method of making a two-phase or multi-phase metallic material

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB734364A (en) * 1952-12-29 1955-07-27 Joseph Barry Brennan Improvements in or relating to the production of metal strip
US3670400A (en) * 1969-05-09 1972-06-20 Nat Res Dev Process and apparatus for fabricating a hot worked metal layer from atomized metal particles
JPS5311834A (en) * 1976-07-20 1978-02-02 Nippon Steel Corp Method of continuously casting molten metal
JPS5412249A (en) * 1977-06-28 1979-01-29 Matsushita Electric Ind Co Ltd Saw-tooth wave generator
JPS5921451A (ja) * 1982-07-28 1984-02-03 Mitsubishi Heavy Ind Ltd 連続鋳造装置
DE3406036A1 (de) * 1984-02-20 1985-08-22 Mannesmann AG, 4000 Düsseldorf Verfahren und einrichtung zum erzeugen von duennen metallstraengen aus metallschmelze, insbes. von stahlstraengen

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1262471A (en) * 1968-05-14 1972-02-02 Nat Res Dev Improvements relating to the fabrication of articles
US4114251A (en) * 1975-09-22 1978-09-19 Allegheny Ludlum Industries, Inc. Process for producing elongated metal articles
JPS5573448A (en) * 1978-11-24 1980-06-03 Matsushita Electric Ind Co Ltd Quick solidifying method of melt
JPS5732854A (en) * 1980-08-08 1982-02-22 Hitachi Ltd Producing device for amorphous metallic tape
JPS5788951A (en) * 1980-11-19 1982-06-03 Sanyo Electric Co Ltd Production of anode blank material for electrochemical potential storage element
GB2115014A (en) * 1982-02-23 1983-09-01 Nat Res Dev Method of making a two-phase or multi-phase metallic material
US4420441A (en) * 1982-02-23 1983-12-13 National Research Development Corp. Method of making a two-phase or multi-phase metallic material

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4738712A (en) * 1985-04-19 1988-04-19 National Research Development Corporation Metal forming
US4834832A (en) * 1985-09-04 1989-05-30 Wacker-Chemitronic Gesellschaft Fur Elektronik-Grundstoffe Mbh Process and apparatus for the manufacture of silicon rods
US5343926A (en) * 1991-01-02 1994-09-06 Olin Corporation Metal spray forming using multiple nozzles
US6296043B1 (en) 1996-12-10 2001-10-02 Howmet Research Corporation Spraycast method and article
US6063212A (en) * 1998-05-12 2000-05-16 United Technologies Corporation Heat treated, spray formed superalloy articles and method of making the same
CN100374612C (zh) * 2005-12-26 2008-03-12 内蒙古科技大学 金属雾化喷射连续生产双金属薄板、薄带的工艺及设备
CN106552908A (zh) * 2016-12-02 2017-04-05 苏州金江铜业有限公司 一种短流程高纯铍箔制备方法

Also Published As

Publication number Publication date
GB2155376B (en) 1987-05-13
EP0155791A2 (de) 1985-09-25
JPS60227952A (ja) 1985-11-13
GB8505477D0 (en) 1985-04-03
DE3570381D1 (en) 1989-06-29
GB2155376A (en) 1985-09-25
JPH0736939B2 (ja) 1995-04-26
EP0155791A3 (en) 1987-10-14
CA1215520A (en) 1986-12-23
GB8405982D0 (en) 1984-04-11
EP0155791B1 (de) 1989-05-24

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